FACE PLUMBING ADAPTER FOR A HEAT EXCHANGER ASSEMBLY

Abstract

A face plumbing adapter having a block portion and a camber portion is provided for a manifold of a heat exchanger assembly. The block portion includes an external planar face, a first mating surface opposite that of the planar face, and an aperture having a B-axis extending through the planar face and first mating surface. The camber portion extends integrally from the block portion in a direction away from the planar face and curving inward toward the B-Axis. The camber portion is biased toward the block portion such that the face plumbing adapter would clinch onto the manifold. The block and camber portions include respective mating surfaces that are complementary to the exterior surface area of the manifold onto which the mating surfaces are affixed.

Description

TECHNICAL FIELD OF INVENTION

The present invention relates to a heat exchanger assembly; more particularly, to a face plumbing adapter for a heat exchanger assembly.

BACKGROUND OF INVENTION

Air conditioning and heat pump systems for residential and commercial applications are known to employ modified automotive heat exchanger assemblies because of their high heat transfer efficiency, durability, and relative ease of manufacturability. A typical automotive heat exchanger assembly includes an inlet manifold, an outlet manifold, and a plurality of multi-port refrigerant tubes hydraulically connecting the inlet and outlet manifolds. The core of the heat exchanger assembly is defined by the plurality of refrigerant tubes and corrugated fins disposed between adjacent refrigerant tubes for improved heat transfer efficiency and increased structural rigidity.

Certain heat exchanger applications and packaging considerations may require face plumbing of the heat exchanger assembly, in which the inlet and/or outlet connections and associated pipes are within the heat exchanger face dimensions. In other words, at least one of the inlet and/or outlet connections to the manifolds extends substantially perpendicular to the plane on which the core lies. This provides maximum use of the packaging space for heat transfer surface area. A known method to accomplish this to mill an opening equal to the desired diameter of the pipe connection in an area of the manifold that faces the same direction as the core. After the heat exchanger is assembled and brazed, an aluminum pipe is positioned over the opening such that the pipe extends perpendicular to the plane on which the core lies, fixtured, and welded in place. This process is labor intensive resulting in increases in time consumption and cost to manufacture such a heat exchanger assembly.

It is desirable to have a robust face plumbing adapter for a heat exchanger assembly that is simple and cost effective to manufacture, as well as easily attaches onto a manifold of a heat exchanger assembly, in which the face plumbing adapter enables face plumbing of the heat exchanger assembly.

SUMMARY OF THE INVENTION

A face plumbing adapter having a block portion and a camber portion is provided for a manifold of a heat exchanger assembly. The block portion includes an external planar face, a first mating surface opposite that of the planar face, and an aperture having a B-axis extending through the planar face and first mating surface. The camber portion extends integrally from the block portion in a direction away from the planar face and curving inward toward the B-Axis. The camber portion is biased toward the block portion such that the face plumbing adapter would clinch onto the manifold. The block and camber portions include respective mating surfaces that are complementary to the exterior surface area of the manifold onto which the mating surfaces are affixed.

A heat exchanger assembly is also provided having a manifold defining a manifold aperture, a plurality of tubes extending from the manifold in a parallel arrangement perpendicular to the A-axis of the manifold, and a plurality of fins disposed between adjacent tubes, thereby defining a heat exchanger core. A face plumbing adapter is affixed onto the manifold, enabling the manifold to have a plumbing connection perpendicular to the heat exchanger core. The face plumbing adapter includes a first portion having a face defining a first portion aperture and a second portion extending integrally from the first portion in a direction away from the face. The second portion is biased toward the first portion such that the face plumbing adapter is clinched onto the manifold, in which the first portion aperture lies in a plane parallel to the core heat exchanger assembly and is in hydraulic communication with the manifold aperture.

The embodiment of the face plumbing adapter allows the use of known standard plumbing methods to provide for a plumbing connection to a manifold to extend in a direction that is substantially perpendicular to the core. The face plumbing adapter replaces the more costly process of milling a hole onto the manifold and welding a connection to the manifold. Further features and advantages of the invention will appear more clearly on a reading of the following detailed description of an embodiment of the invention, which is given by way of non-limiting example only and with reference to the accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

This invention will be further described with reference to the accompanying drawings in which:

FIG. 1 shows a perspective front view of an exemplary embodiment of a face plumbing adapter engaged to a manifold of a heat exchanger assembly.

FIG. 2 shows a partial perspective rear view of the face plumbing adapter engaged to the manifold of the heat exchanger assembly of FIG. 1.

FIG. 3 is an end view of the face pluming adapter of FIG. 1 showing an interior surface having a bore with an end wall defining an aperture.

FIG. 4 is a side view of the face pluming adapter of FIG. 1 showing the interior mating surfaces of the face plumbing adapter.

FIG. 5 is a partial cross sectional view of the manifold of the heat exchanger assembly of FIG. 2 taken along line 5-5.

FIG. 6 is a cross sectional view of the face plumbing adapter of FIG. 4 taken along line 6-6.

DETAILED DESCRIPTION OF INVENTION

Referring to FIGS. 1 through 6, wherein like numerals indicate corresponding parts throughout the several views, is an exemplary embodiment of a heat exchanger assembly 20 having a face plumbing adapter 100. The face plumbing adapter 100 enables an inlet and/or outlet plumbing connection 30 to a manifold 22, 24 to extend in a direction substantially perpendicular to the core 34 of the exchanger assembly 20. The face plumbing adapter 100 may be snapped or clinched onto the exterior surface of the manifold 22, 24 and affixed in place by brazing.

Shown in FIG. 1 is a perspective front view of an exemplary embodiment of the face plumbing adapter 100 engaged to a manifold 22 of the heat exchanger assembly 20. The heat exchanger assembly 20 includes a first manifold 22 extending along a manifold A-axis and a second manifold 24 extending in a spaced and substantially parallel relationship with the first manifold 22. The first and second manifolds 22, 24 present a plurality of corresponding tube slots 26 spaced along the respective manifolds 22, 24. A plurality of fluid tubes 28 is inserted into the corresponding tube slots 26 of the manifolds 22 in a parallel arrangement for hydraulic fluid communication between the manifolds 22, 24. A plurality of corrugated fins 32 is inserted between adjacent fluid tubes 28 for increased heat transfer efficiency between the fluid in the tubes 28 and a stream of ambient air. The plurality of tubes 28 and corrugated fins 32 between adjacent tubes 28 define the heat exchanger core 34, which lies on a plane P.

Affixed to the first manifold 22 is the face plumbing adapter 100, which enables the plumbing connection 30 to the first manifold 22 to extend substantially perpendicular to the core 34. Substantially perpendicular to the core 34 means that the plumbing connection 30 extends in a direction about 80 to 100 degrees, preferably 90 degrees, relative to the plane P in order to meet the packaging requirements of certain applications.

Referring to FIGS. 2 and 5, in which FIG. 2 shows a partial perspective rear view of the face plumbing adapter 100 engaged to the manifold 22 and FIG. 5 shows a partial cross sectional view of the face plumbing adapter 100 of FIG. 2. The face plumbing adapter 100 includes a first portion 102 and a second portion 104 biased toward the first portion 102 such that the face plumbing adapter 100 snaps and clinches onto the exterior surface of the manifold 22. The first portion 102 may block shape, block portion 102, and the second portion 104 may have a camber shape, camber portion 104. The block portion 102 includes an external planar face 108 and defines a block aperture 128 having a central B-Axis. The camber portion 104 extends integrally from the block portion 102 in a direction away from the planar face 108 and curves inward toward the central B-axis. The block portion 102 also includes an edge 110 opposite from the camber portion 104, in which the edge 110 defines a nose 112 having an undercut 114.

Best shown in FIG. 4, is a side view of the face plumbing adapter 100 of FIG. 1 showing the interior surfaces 116 of the face plumbing adapter 100. The block portion 102 includes a first mating surface 118 and the camber portion 104 includes a second mating surface 120. The first and second mating surfaces 118, 120 are complementary to exterior surface area of the manifold 22 onto which the first and second mating surfaces 118, 120 are affixed. Once the face plumbing adapter 100 is assembled onto the manifold 22, the nose 112 section of the block portion 102 cooperates with the biased camber portion 104 to clinch the face plumbing adapter 100 onto the exterior mating surface area of the manifold 22 as shown in FIGS. 1 and 2.

Best shown in FIG. 3, the block portion 102 defines a bore 122 having a bore end 124 surrounded by a bore side wall 126, in which the bore 122 is in hydraulic communication with the block aperture 128. The bore 122 extends in a direction parallel to the B-axis and may be concentrically located with the block aperture 128. The bore 122 may have a diameter larger than the diameter of the block aperture 128 such that a ledge 130 is defined between the block aperture 128 and the bore side wall 126. A portion of the manifold 22 onto which the face plumbing adapter 100 is affixed defines a manifold aperture 132 that is smaller than the bore 122 diameter. The larger bore diameter allows multiple sizes of block aperture 128 to be milled through the planar face 108 to accommodate various size piping connections. The bore 122 provides hydraulic communication between the block aperture 128 and manifold aperture 132.

Referring to FIG. 6, in the manufacturing of the face plumbing adapter 100, the drilling of the bore 122 from the back side of the face plumbing adapter 100 defines the two prongs 106 having a V type configuration on a distal end of the camber portion 104. This V type configuration together with the undercut 114 defined by the nose 112 reduces the total surface mating area between the face plumbing adapter 100 and manifold 22, and increases the linear distance available for a braze fillet to form. The increase length of the braze fillet provides a more robust braze joint as opposed to a greater surface mating area.

The face plumbing adapter 100 may be continuously extruded from aluminum and then cut into multiple units, each having a desired dimension to accommodate different size clinching of production couplers. A common manifold aperture 132 size can be milled into the manifold 22 for most applications while only milling the block aperture 128 to the desired design criteria, thereby reducing set up time and manufacturing cost.

The embodiment of face plumbing adapter 100 of the invention allows the use of known standard plumbing methods to provide for a plumbing connection 30 to a manifold 22 of the heat exchanger assembly 20, in which the plumbing connection 30 extends in a direction that is substantially perpendicular to the plane P on which the core 34 lies. The interface of the bore 122 between the block aperture 128 and manifold aperture 132 allows a wider tolerance between the size the manifold 22 aperture and block aperture 128. This is advantageous, since the manifold aperture 132 may be standardized and the block aperture 128 can be milled to provide the desired flow rate for different applications, or vice versa. Another advantage is that the face plumbing adapter 100 replaces the more costly process of milling a hole onto the manifold 22 and welding a connection to the manifold 22.

While this invention has been described in terms of the preferred embodiments thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow.

Claims

1. A face plumbing adapter for a manifold of a heat exchanger assembly, comprising: a block portion having an external planar face and an opposite first mating surface, wherein said block portion defines a block aperture extending along a center B-Axis through said planar face and said first mating surface;a camber portion extending integrally from said block portion in a direction away from said planar face and curving inward toward said B-Axis, wherein said camber portion includes a second mating surface extending from said first mating surface, andwherein said first mating surface and said second mating surface are complementary to the exterior surface area of the manifold onto which the said mating surfaces are affixed.

2. The face plumbing adapter for a manifold of a heat exchanger assembly of claim 1, wherein said block portion includes an edge defining a nose opposite from said camber portion.

3. The face plumbing adapter for a manifold of a heat exchanger assembly of claim 2, wherein said camber portion includes a distal end defining two prongs.

4. The face plumbing adapter for a manifold of a heat exchanger assembly of claim 3, wherein said nose and said at least two prongs are configured to cooperate in engaging the manifold such that the face plumbing adapter is clinched onto the manifold.

5. The face plumbing adapter for a manifold of a heat exchanger assembly of claim 4, wherein said nose defines an undercut and said at least two prongs defines a V-shape, thereby increasing the linear distance available for forming a braze fillet.

6. The face plumbing adapter for a manifold of a heat exchanger assembly of claim 5, wherein: said first mating surface defines a bore having a larger diameter than the diameter of said block aperture, andsaid bore includes an end wall circumscribing said block aperture, thereby defining a ledge.

7. The face plumbing adapter for a manifold of a heat exchanger assembly of claim 6, wherein: said block aperture extending along the center B-axis is 80 to 100 degrees relative to said planar face;said bore extends parallel to the center B-axis of said block aperture; andsaid prong includes a distal end immediately adjacent to the center axis of said block bore.

8. The face plumbing adapter for a manifold of a heat exchanger assembly of claim 7, wherein said camber portion is biased toward said block portion such that the face plumbing adapter clinches onto the manifold.

9. The face plumbing adapter for a manifold of a heat exchanger assembly of claim 8, wherein said block aperture extending along the center B-axis is perpendicular to said planar face.

10. A face plumbing adapter for a manifold of a heat exchanger assembly, comprising: a first portion having an planar face and an opposite first mating surface, wherein said first portion defines an aperture extending through said planar face and said first mating surface along a central B-axis; anda second portion having a second mating surface extending integrally from said first portion in a direction away from said planar face and curving toward the central B-axis such the face plumbing adapter may be clinched onto the manifold;wherein said first mating surface and said second mating surface are complementary to the exterior surface area of the manifold onto which the said mating surfaces are affixed.

11. A face plumbing adapter for a manifold of a heat exchanger assembly of claim 10, wherein: said first portion defines a bore in said first mating surface, andsaid bore includes diameter a larger than the diameter of said aperture.

12. A face plumbing adapter for a manifold of a heat exchanger assembly of claim 11, wherein said second portion is biased toward said first portion such that said face plumbing adapter clinches onto the heat exchanger assembly.

13. A face plumbing adapter for a manifold of a heat exchanger assembly of claim 12, wherein said bore and V-shaped configuration of prong is formed concurrently.

14. A face plumbing adapter for a manifold of a heat exchanger assembly of claim 13, wherein said bore includes an end wall circumscribing said block aperture, thereby defining a ledge.

15. A heat exchanger assembly comprising: a manifold extending along an A-axis, said manifold includes a side defining a manifold aperture;a plurality of tubes extending from said manifold in a parallel arrangement perpendicular to the A-axis;a plurality of fins disposed between adjacent tubes, thereby defining a heat exchanger core lying on a plane P; anda face plumbing adapter including a first portion having a face defining a first portion aperture about a B-axis and a second portion extending integrally from said first portion in a direction away from said face,wherein said second portion is biased toward said first portion such that said face plumbing adapter is clinched onto said manifold in which said first portion aperture lies in a plane parallel to the plane P and is in hydraulic communication with said manifold aperture.

16. The heat exchanger assembly of claim 15, wherein: said first portion is a block portion having said face parallel to plane P; andsaid second portion is a camber portion extending integrally from said block portion in a direction away from said face and inward toward B-Axis.

17. The heat exchanger assembly of claim 16, wherein: said first portion includes a surface opposite from said face, said surface defines a bore having a diameter larger than the diameter of said first portion aperture,wherein aid bore is in hydraulic communication with said manifold aperture and said first portion aperture.

18. The heat exchanger assembly of claim 17, wherein said camber portion includes a distal end includes two prongs defining a V-shape.

19. The heat exchanger assembly of claim 17, wherein said block portion includes a nose includes an edge defining a nose opposite from said camber portion.